Modular Foundation for a Mattress

ABSTRACT

A bedding foundation for ensuring lightweight and easy delivery, and assembly. The foundation comprises modular components which are easily produced and assembled. The foundation consists of multiple joints, which are connected by a series of rods running parallel and/or perpendicular to one another. The foundation may be elevated by a series of plastic leg supports or casters. The foundation may be covered along its top side by a panel and/or surrounded on one or more sides by a fabric cover.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. ProvisionalApplication Ser. No. 62/100,975 filed Jan. 8, 2015 and entitled ModularFoundation for a Mattress, which is incorporated by reference herein.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to box frames and mattressfoundations.

2. Description of the Related Art

Conventional bedding systems consist of a mattress, a foundation or boxspring, and a metal frame or platform. Various sizes are commerciallyavailable (e.g., king, queen, full, twin, twin XL). For illustration, aking size bedding system is the size of two twin XL systemsside-by-side. Related to this comparison, most king size box springsmust be split for shipping and delivery. Not surprisingly, shipping anddelivery greatly impacts costs associated with bedding systems. Shippingand delivery are critical considerations to the present invention.Additionally, users often complain about the noise associated withconventional mattress boxes.

A mattress is usually supported by a box spring or foundation, andfurther elevated by a metal frame. Typically, a box spring is made outof metal and wood whereas a foundation is made entirely out of wood.Both box springs and foundations have evolved through the years and areavailable in a variety of configurations. Prior configurations, however,have been clunky, heavy, and expensive. The present invention solvesthese problems.

Since the introduction of foam mattresses (e.g., memory foam, latex,gel-infused, air number), which can be compressed and packaged intosmall boxes, companies have been selling and shipping foam mattressesvia FedEx®, UPS®, and other couriers with greater ease. Box springs andfoundations, however, failed to advance, and remain difficult to ship.As alluded to, shipping mattress foundations and box springs is costprohibitive.

BRIEF SUMMARY OF THE INVENTION

The present invention is a mattress foundation that can be disassembledand packaged into a small box and shipped efficiently. Certainembodiments include leg supports, which further eliminate the need for ametal frame. By using plastic connector pieces, and a series oflightweight rods, the present invention is easy to produce, transport,and assemble. Additionally, and in most embodiments, it is easy toconvert between sizes by changing some of the components.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a top, right, and rear side isometric view of a firstembodiment of the present invention.

FIG. 2 is a bottom, right, and front side isometric view thereof.

FIG. 3 is a top, left, and rear side isometric view of a combination ofcomponents of the present invention.

FIG. 4 is a perspective view of some of the components depicted in FIG.3.

FIG. 5 is a top plan view of the combination of components depicted inFIG. 3.

FIG. 6 is a right plan view of the combination of components depicted inFIG. 3.

FIG. 7 is a perspective view of a segment of a connecting bar of theinvention.

FIG. 8 is perspective view of a segment of a connecting bar of theinvention.

DETAILED DESCRIPTION OF THE INVENTION

The following is a description of the preferred embodiments of amattress foundation that can be easily assembled/disassembled, packagedand/or otherwise transported.

FIG. 1 illustrates a box frame 20 generally having a series of jointsconnected by rods and columns supported by caster wheels and covered bya cover. More specifically, the box frame 20 of FIG. 1 comprises pairsof joints 22, which are oriented either upwardly and downwardly. Eachjoint 22 oriented upwardly is connected to a joint 22 orienteddownwardly by a column 26.

FIG. 1 further illustrates a variety of metal rods connecting the joints22. For instance, some of the joints are connected by corner connectingrods 28. Other joints are connected by long cross rods 30, short crossrods 32, or side rods 34.

Where a first upward joint 22 is connected to a second upward joint 22by a particular connecting rod 28, 30, 32, 34, a first downward joint 22(connected to the first upward joint 22 via a first column 26) isconnected to a second downward joint (connected to the second upwardjoint 22 via a second column 26) by the same type of connecting rod. Forexample, where a first upward joint 22 is connected to a second upwardjoint 22 by a first corner connecting rod 28, the first lower joint 22is connected to the second lower joint 22 by a second corner connectingrod 28.

FIG. 1 further illustrates casters 36 connected to each of the joints 22oriented downwardly. Some embodiments will include casters for easymovement of the box frame. The embodiment illustrated in FIG. 1 alsoincludes a cover 38 positioned above and generally flush with the top ofthe upper joints 22 and the series of connecting rods 28, 30, 32, 34that connect the upward joints 22. As illustrated in FIG. 1, the cover38 comprises nine similar panels that are secured to one another. Thecover unit may be constructed from a number of materials includingplastic and/or cardboard. The cover unit may also be constructed offabric and held in place by rods or other means. For shipment andtransit, the cover unit is ideally collapsible, foldable, stackable orotherwise easy to transport. These characteristics should not beconstrued as limiting, however.

FIG. 2 illustrates a different perspective of the embodiment depicted inFIG. 1. Although FIG. 2 does not expressly illustrate unique elementsthat were not otherwise depicted in FIG. 1, FIG. 2 generally illustratesthe complete network of nine pairs of joints 22 and the series ofconnecting rods and columns between the joints. An observer willrecognize, however, that FIG. 2 illustrates that eight of the nine pairsof joints 22 mirror one another, and that the two center joints pairedat the center of the box frame are generally mirrored but perpendicularto one another—in this particular embodiment.

FIG. 3 illustrates some of the attributes of a joints 22 paired andconnected by a column 26. Each of the joints 22 illustrated in FIG. 3are hexagonal prisms (eight faces). Each joint 22 comprises an externalface 50, an internal face 52 (not shown in FIG. 3) opposite the externalface 50, two H-faces (not shown in FIG. 3), a column face 56 (not shownin FIG. 3), a long rectangular face 58 (not shown in FIG. 3), and twoshort rectangular faces 60 (not shown in FIG. 3). In addition to itseight faces, each joint 22 further comprises two rounded triangularorifices 62, two ovular orifices 64, and a rectangular orifice 66. Byincluding the rounded triangular orifices 62 and ovular orifices 64, theuser is able to reduce the weight of each joint—while maintainingstructural integrity—and, therefore, the weight of the overall box frame20. Each joint 22 comprises a big bolt hole 68 (not shown) that runsfrom the long rectangular face 58 into the rectangular orifice 66. Thebig bolt hole 68 allows for a big bolt 70 to be threaded into the joint22 and in some instances through one or more connecting rods, asdiscussed below.

As illustrated, the column 26 passes from the rectangular orifice 66 ofa first joint 22 through the column hole 76 (not shown in FIG. 3) of thecolumn face 56 through the column hole 76 of the column face 56 of thepaired joint 22 and into the second rectangular orifice 66. The column26 maintains appropriate vertical separation between the paired joints22 and reduces lateral shifting between the upper tier of joints and thelower tier of joints.

Each joint 22 also comprises small bolts and nuts 72 that pass throughsmall bolts and nut holes 74 (not shown in FIG. 3). The small bolts andnuts 72 are useful for securing the connecting rods that pass throughthe H-track orifices 78 (not shown in FIG. 3) and into the joint 22. Onewho is skilled in the art will recognize that small bolts and nuts 72are not exactly expressly necessary as other means for securing theconnecting rods in place may suffice.

It should be further noted from FIG. 3 that the space created within therectangular orifice 66 in between the column 26 and big bolt 70, a gapresembling an H-prism exists. The gapped H-prism allows for additionalconnecting rods to extend perpendicularly into and/or through the joint22.

FIG. 4 illustrates a different perspective of one of the joints 22. FIG.4 illustrates some of the attributes previously discussed, but nototherwise illustrated from FIG. 3. For instance, FIG. 4 illustrates oneof the H-faces 54, the column face 56, both of the short rectangularfaces 60, as well as the column hole 76 and one the H-track orifices 78.FIG. 4 does not illustrate a column or any connecting rods passingthrough the joint 22.

FIG. 5 illustrates a top plan perspective of a joint 22. The perspectiveillustrated in FIG. 5 reflects the long rectangular face 58 as well asthe big bolt 70 as it rests in the big bolt hole 68 (not shown in FIG.5).

FIG. 6 illustrates the paired joints 22 previously illustrated in FIG.3, but from a different perspective. FIG. 6, in particular, illustratesthe joints generally from the perspective of one of the sides of H-faces54 and short rectangular face 60. FIG. 6 illustrates the small bolts andnuts 72 as they pass through the small bolts and nuts hole 74 as well asthe H-track orifices 78.

FIGS. 7 and 8 illustrate two ends for potential connecting rods. Morespecifically, FIG. 7 illustrates one end of a connecting rod. Theconnecting rod is an H-track, shaped so that it will fit through anH-track orifice 78 of a joint 22. The end portion of this particularconnecting rod comprises two eye holes 80 which align with the smallbolts and nut holes 74 of a joint 22 when the connecting rod iscorrectly positioned. Once positioned, small bolts and nuts 72 passthrough the small bolts and nut holes 74 and through the eye holes 80.The small bolts and nuts 72 generally secure the connecting rod to thejoint 22.

FIG. 8 illustrates an alternative end of a connecting rod. Theconnecting rod is an H-track, shaped so that it will fit through arectangular orifice 66 of a joint 22 that is oriented perpendicularly tothe connecting rod. The end portion of this particular connecting rodcomprises an H-track column hole 82 which aligns with the big bolt hole68 of a joint 22 when the connecting rod is correctly positioned. Oncepositioned, a big bolt 70 passes through the big bolt hole 68 andthrough the H-track column hole 82. The big bolt 70 generally securesthe connecting rod to the joint 22.

In alternative embodiments, the present invention consists ofcenterpieces, interlocking pieces and corner pieces that are connectedby a series of rods to form a generally rectangular shaped foundation.These characteristics should not be construed as limiting, however. Incertain embodiments, the foundation may include leg supports and/or afabric cover. Further embodiments share similar attributes but differ inothers. In the embodiments discussed below, a queen and full sizefoundations consist of the same number of corners, interlocks, andcenter support pieces: four, six, and two, respectively. Twin and twinXL sizes as illustrated below, on the other hand, generally consist offour corners, four interlocking pieces, and no center pieces. To furtherdistinguish the embodiments described below, the queen and full sizesystems consist of thirty-four rods, whereas the twin and twin XL sizesconsist of twenty rods. Those of ordinary skill in the art willrecognize that these numbers may be adjusted and include more or lessrods and more or less connecting pieces. And of course, certainembodiments may exist so as to make available king and other sizebedding systems.

The two embodiments discussed here may be described from the perspectiveof the top view and bottoms views, which are generally symmetrical toone another. For convenience, two pieces may be said to be “connected”when those pieces are connected by a top rod and bottom rod—the top rodand bottom rod running parallel to one another.

Certain embodiments consist of four corners, six interlocking pieces,and two center pieces. These plastic pieces connect a grid-like seriesof rods. Each plastic piece, be it corner, interlocking, or center, runsvertically upright in generally uniform height from the bottom of thefoundation to the top of the foundation. Each of the four plastic cornerpieces is connected, at 90°, to the two interlocking pieces adjacent theparticular corner piece. Accordingly, and in this particular embodimentof the invention, each plastic corner piece receives four rods.

This particular embodiment may be further characterized as having ashorter side and a longer side. On either shorter side of thefoundation, two corner pieces are separated by an interlocking piece.Each of those two corner pieces is connected to the interlocking pieceon opposite sides. Also, each of said interlocking pieces connects to acenter piece at 90° from either corner piece. As for either longer sideof the foundation, there are two corner pieces separated by twointerlocking pieces. That arrangement of pieces may be characterized asa straight line comprising corner piece-interlocking piece-interlockingpiece-corner piece. Each of the two longer side interlocking piecesconnects to a corresponding center piece. Said corresponding centerpiececonnects to an opposite longer side interlocking piece. The twocenterpieces of this embodiment are connected to one another. Thus, eachcenterpiece connects to two longer side interlocking pieces which are onopposite longer sides; a shorter side interlocking piece opposite; andthe other center piece opposite said shorter side interlocking piece.

In an alternative embodiment, the foundation consists of four plasticcorner pieces and four interlocking pieces all of which are connected byrods. This particular embodiment, which has no center pieces, may becharacterized as having a shorter side and a longer side. Along theshorter side of the invention, the invention comprises two corner piecesconnected to one another. On the longer sides of the foundation, twocorner pieces are separated by two interlocking pieces. The longer sidemay be characterized as having a sequence of corner piece-interlockingpiece-interlocking piece-corner piece. In addition to connections withthe adjacent corner and interlocking pieces, each interlocking piece isconnected to an additional interlocking piece on the immediatelyopposite interlocking piece on the other longer side of the foundation.

Although the present invention may be constructed in various forms andwith various pieces, certain preferred embodiments will share some orall of the following similar pieces. These pieces, as described below,should not be considered limiting, but merely illustrative. Those ofskill in the art will recognize these pieces may be constructed andcombined in a various other combinations and/or configurations.

Center Piece: The center piece has a bottom end that is generallyidentical to a top end. Each of these two ends may receive four rods.Rods are received and securely fastened along the top and bottom sidesof the center piece at alternating 90° angles—forming a cross whenviewed from above or below. Certain embodiments of the center piece(corner pieces, or interlocking pieces, as well) include a lockingmechanism (e.g., pull apart ball bearing release) for securing the rodsin place. Each center piece runs from the bottom of the foundation tothe top of the foundation. Also, the receiving portions of the centerpieces have a gothic like curvature for ensuring additional structuralintegrity.

Corner Piece: The corner piece has a bottom end that is generallyidentical to a top end. Each of these two ends may receive two rods.Each corner piece receives rods running perpendicular to one anotherwhen viewed from above and below. In preferred embodiments the cornerpieces are curved so as to avoid jagged or sharp edges. Also, thereceiving portions of the corner pieces have a gothic like curvature forensuring additional structural integrity. Additionally, in preferredembodiments of the invention, the corner piece is flat on its top andbottom sides. That is, the bottom and top sides of the corner is of aflush plane.

Interlocking Piece: The interlocking piece has a bottom end that isgenerally identical to a top end. Each of these two ends may receivethree rods. By having flush surfaces, materials such as blankets orother bedding more easily cover the foundation as discussed below. Also,the receiving portions of the interlocking pieces have a gothic likecurvature for ensuring additional structural integrity. In certainembodiments of the invention, the outer side of the interlocking pieceis a flush surface and the top and bottom sides of the interlockingpieces are flush surfaces.

Rod: The rod may vary in length between various embodiments and within aparticular embodiment. The rods are lightweight and frequently made ofmaterial such as fiber glass or aluminum. Those of ordinary skill in theart will recognize that these materials should not be construed aslimiting. The primary limitation on material is that the final structuremust support the weight of a mattress and people resting above. In mostembodiments, each rod is of a fixed length and has two ends. Each ofsaid ends is typically identical to the other end and may becharacterized as having a tenon—as commonly used in wood workingapplications. The tenon like end of a rod in certain embodiments willhave a hole on two opposing sides to correspond with the lockingmechanism used in certain embodiments with the other connecting pieces,(e.g. center, corner, and interlocking) of the foundation.

Accordingly, the receiving portions of the other pieces resemble amortise. The length of the rod in most embodiments will be of a uniformshape and dimension, however, this is not limiting. In most embodiments,that shape will be a rectangular prism: of course, the shape may come intriangles or circles etc. in other embodiments. As discussed above, thelength of the rod will frequently correspond with the size of thefoundation.

Fabric Cover: In certain embodiments of the invention, the foundationmay be surrounded on one or more sides with a special fabric cover. Insome of those embodiments this cover will be waterproof, and in somecases, one-hundred percent waterproof. In most embodiments in which thecover is used, the cover will fit snugly around five of the six sides ofthe foundation.

Panel: In certain embodiments of the invention, the foundation may begenerally covered along its top face by a panel. Although the dimensionsof the panel are not necessarily limited by the dimensions of thecorresponding mattress or the foundation, the edges of the panel will,in most embodiments, be flush with the edges of the foundation. Also, itis anticipated that most often, the cover will be of a recyclablematerial and will be characterized as a folding thermoplastic panel withlocking system. In some instances, the panel will be characterized as agrid-like structure. If both a fabric cover and panel are included in aparticular embodiment, the panel will most frequently be placed over thefoundation, and the fabric cover will be placed over the foundation andpanel.

Leg Support: In certain embodiments of the invention, the foundationwill be elevated by leg supports. Use of these legs supports willeliminate the need for a metal frame between the ground and thefoundation. These leg supports are lightweight and of great structuralintegrity. In some embodiments, the leg supports are identical to oneanother, although this is not limiting. For those embodiments includingleg supports, there will be a leg support for each of the connectingpieces (e.g. corner, center, and interlocking). In the embodimentsdiscussed in detail above, there will be twelve or eight leg supportsdepending on the given size of the foundation. Of course, and asdiscussed above, because various embodiments may include differentnumbers of corner pieces, center pieces, or interlocking pieces, thenumber of leg supports may vary as well. Although those connectingpieces have been discussed above as being symmetrical latitudinally,that is, they have been characterized as having identical top and bottomportions, the greatest distinction between the top and bottom portionsis that in those embodiments in which the invention includes legsupports, the bottom of each connecting piece will have a hole orreceiving component to ultimately receive its corresponding leg support.The receiving component between the respective connecting pieces and legsupports may vary between embodiments. The leg support might be threadedon the end to be received by a threaded hole or receiving component ofthe connecting piece. However, in other embodiments, the leg support maysimply slide right into a receiving portion of each connecting piece.Alternatively, the leg support and receiving component of eachconnecting piece may have one or more locking mechanisms. Those familiarin the art will recognize the various possibilities.

In most embodiments incorporating leg supports, the leg supports will becharacterized as having two ends—a top end and a bottom end. The top endof the leg support will connect to one of the respective connectingpieces in the foundation. The bottom end of the leg support, however,will remain securely on the ground or some other surface to support theweight of the bedding system. In most embodiments, the top end of theleg support will be narrower than that of the bottom end. In certainembodiments, the leg support will appear similar to that of a cone or arounded cone.

In certain embodiments, this invention is made of durable material,which may include metal, plastic, fiberglass, or a number of othermaterials. Metal can come from machined aluminum, aluminum weldment orcastings, or similar steel or alloy. Molded or machine plastic can beused with recommended strengthening and stiffening features like ribs orother sectioning techniques. In a preferred embodiment, the materialswill be of very lightweight. The particular thickness and otherdimensions of the materials are not particularly important, so long asthe pieces are necessarily durable for the purpose of securing andstabilizing a mattress and one or more persons above. In mostembodiments, the invention will include various nuts, bolts, screws,etc. for securing leg supports or rods to connecting pieces. The lengthand width of the rods and pieces may be of varying dimension. The use ofnuts, bolts, screws, etc. is not expected in most embodiments, however.

Once the respective rods, connecting pieces, leg supports and cover ofthe invention (or any combination or absence thereof) is produced, thosepieces that have produced can be packaged into a box for shipping anddelivery. Given the lightweight and size of these pieces, the size andweight of the overall shipped product is easy to transport. The ultimateconsumer or user can easily remove the pieces from the packaging andquickly assemble. In most embodiments, the user can do so without theneed for screws or tools. As discussed above, the user can take the rodsand quickly secure them and fasten them into the appropriate connectingpieces (e.g. corner, center, interlocking). Once the ultimate grid-likeseries of rods are secured within the appropriate connecting pieces, theuser may attach the leg supports (if included with a particularfoundation). If leg supports were not included, the foundation may beplaced on top of a metal frame. Then the user may cover the foundationwith the fabric cover and/or panel (if included with the particularfoundation). Once these steps have been followed, as appropriate, theuser may place a mattress above the foundation.

It will be appreciated by persons skilled in the art that numerousvariations and/or modifications may be made to the invention as shown inthe specific embodiments without departing from the spirit or scope ofthe invention as broadly described. The present embodiments are,therefore, to be considered in all respects as illustrative and notrestrictive. Other features and aspects of this invention will beappreciated by those skilled in the art upon reading and comprehendingthis disclosure. Such features, aspects, and expected variations andmodifications of the reported results and examples are clearly withinthe scope of the invention where the invention is limited solely by thescope of the following claims.

1. A bedding foundation comprising: a. a first corner piece connected toa second corner piece; b. said first corner piece connected to a firstinterlocking piece; c. said first interlocking piece connected to asecond interlocking piece; d. said second corner piece connected to saidsecond interlocking piece; e. said first interlocking piece connected toa third interlocking piece; f. said third interlocking piece connectedto a fourth interlocking piece; g. said second interlocking piececonnected to said fourth interlocking piece; h. said third interlockingpiece connected to a third corner piece; i. said third corner piececonnected to a fourth corner piece; and j. said fourth interlockingpiece connected to said fourth corner piece.
 2. The bedding foundationof claim 1, wherein a fabric piece covers one or more sides of thebedding foundation.
 3. A foundation comprising: a. an upper matrixcomprising a first plurality of joints connected by a first series ofconnecting rods; b. a lower matrix comprising a second plurality ofjoints connected by a second series of connecting rods; c. the secondplurality of joints being equal in quantity to the first plurality ofjoints; d. each joint from the second plurality of joints correspondingto a joint from the first plurality of joints; and e. each joint fromthe second plurality of joints connected to the corresponding joint fromthe first plurality of joints by a column.
 4. The foundation of claim 3further comprising: a. a plurality of casters, each of said castersconnected to a joint from the second plurality of joints.
 5. Thefoundation of claim 3 further comprising: a. a cover unit positionedabove the upper matrix.
 6. The foundation of claim 4 wherein: a. thecover unit comprises one or more segments.
 7. The foundation of claim 5wherein: a. the one or more segments of the cover unit are eitherstackable or foldable.
 8. The foundation of claim 3 wherein: a. one ormore of the first series of connecting rods are H-track at least inpart; and b. one or more of the second series of connecting rods areH-track at least in part.
 9. A foundation joint comprising a hexagonalprism.
 10. The foundation joint of claim 9 wherein the hexagonal prismhas one or more orifices.
 11. The foundation joint of claim 10 whereinat least one of the one or more orifices can receive an H-track.
 12. Thefoundation joint of claim 9 wherein the hexagonal prism is a rightprism.